Clarke 4.3 Gal. install

Slideshow:


Stills and info:

Fresh outta the box...


It'll never be this clean again!


Molding excess blocking the hole.


Because of the step up over the oring I have to open the hole to 1/2 inch.


Ideally I would use a Uni-bit/Stepped Bit for this material but I don't have one the right size. For the little bit I had to remove the boring bit worked fine.


The opened up hole, even after the bit I still had to run the tip of a utility knife around the inside lip of the hole to remove the last bit of "fluff".


All the excess "fluff" from inside the hole next to the petcock for size referance.


Mounts and petcock on the new tank.


Breather Vent from the old cap on the new one.


Stock seat screw and tank strap.


I can still reach the choke lever while seated on the bike.


Left side clearances around the tank.


Still room for my enlarged wiring harness etc.


The stock hose looks like it might need a trim but don't be fooled!


Still fits, just a little differently.


Right side clearances around the tank.


Right side clearances around the tank.


Left front clearances for wires and cables.


Slight contact at full lock, I'm not concerned.


All done, left side.

All done, right side.

Now it's time to fill 'er up and try it out!

Great info, I know your not concerned but I am about the lsight contact, is there nowt you can do about it ?.
Also any chance I could copy your photo's & txt to add to the service section of our website ?... www.xr650r.co.uk always a good thing to have for others to share.

I don't know if the contact at full lock could be due to a misalignment or irregularity of the tank molding. I also have HDB upper bar clamps which hang back a bit farther than stock. It doesn't touch at full lock the other way but is fairly close leading me to believe that the tank is lined up pretty evenly. I know that Clarke was having manufacturing issues recently as this is the reason I was given for the long delay in getting my tank.

As far as sharing this info, go for it, that's why I post it. In my opinion, once it's posted online it's public info anyway.

BTW anyone know if this is normal for the filter screen to look this way?!

looks squashed to me like someones gripped it to pull it off, also the plastic 'legs' look like they are cracking(?), still as long as the filter mesh is intact it will still do its job.

Yeah it does, but it's never been out of the tank before the swap. Low miles, one owner, me. I know I didn't do that so I guess the gas may do that to them?

Might be worth pulling the strainer off and checking the pipe inside.....

I couldn't work out why my reserve didn't last too many miles lol

Wow! Is that a rust hole?
I'm planning on pulling the strainer soon and doing the "over the hump" siphon tube mod and just installing a new hose between the petcock and carb so I can install an inline filter. I should change the oring too while I'm in there.

DirtyErnie wrote:Wow! Is that a rust hole?
I'm planning on pulling the strainer soon and doing the "over the hump" siphon tube mod and just installing a new hose between the petcock and carb so I can install an inline filter. I should change the oring too while I'm in there.

Not sure about rust as it's brass.....but whatever it was it rusted through; small work with soldering iron and it's good as new

that would be corrosion

non ferrous metal corrodes - ferrous metal rusts

Only one small problem to report on my ride today. I should have noticed this one right away during install....

Not a big deal, loosen the clamp and turn it, retighten. Good to go.

Than you for probably the best "how to do it" video I have seen here! That exact tank, Rox risers and a "tall seat" are next up for me, of course that will be secondary to a BD dual sport kit if the state of Ca allows me to register my BRP of the road. Thanks again.

ive just fitted my clarke 4.3 with chinese radiators+ a fcr carb, i had to bend the r/hand rad mt,to gain clearence around top rad hose, i also heat molded the tank to get clearance around carb [ which im converting to l/hand cable operation], ive also added a l/hand petcock which ill link up to r/hand tap via hoses, all good fun

Let's see the results of your labor! Post up some pictures of those modifications!

l just found this topic and read it and all , same tank l'm installing on my 650r
Whats this he's talks about the over the hump mod
Quote "I'm planning on pulling the strainer soon and doing the "over the hump" siphon tube mod and just installing a new hose between the petcock and carb so I can install an inline filter. "

thanks mike

this my red version of same tank , l received it yesterday , will install in spring -35 Celcuis last few days COLD . l find this topic great for my new tank wish l had fouund it earlier wouldn't of had to start my own tread.GREAT INFO
thanks mike

xr honda to the max wrote:l just found this topic and read it and all , same tank l'm installing on my 650r
Whats this he's talks about the over the hump mod
Quote  "I'm planning on pulling the strainer soon and doing the "over the hump" siphon tube mod and just installing a new hose between the petcock and carb so I can install an inline filter. "

thanks mike

There's a trick a few guys on here have done to increase the ability of using the gas in the far side of the tank. They run a fuel line inside the tank "over the hump" to the far side from the petcock to drain that side first and then the petcock side is reserve. No tipping the bike to get the gas from the other side. Still haven't done the mod. Been having too much fun with the bike as-is. I'll see if I can post a link to that....

thanks dirty Erinie
if you find link that would be great was thinking to do a second pet cock but it has to work or tank is no longer any good
mike

xr honda to the max wrote:thanks dirty Erinie
if you find link that would be great was thinking to do a second pet cock but it has to work or tank is no longer any good
mike

I think this is the link we are talking about:

http://www.advrider.com/forums/showthread.php?t=409774&page=621

Jipperr's post about "trick tank"

thanks DOUG C
great will doo
mike

That's the one, thanks!

where doo l get that fuel line that goes into tank from pet cock over the hump , which doen't fade away in fuel ??Would it be a good idea to put a check valve on it also not just a weight simular to a skidoo so no drain back . Would one get a air lock ?
just thinking out load

thanks mike

I think it was MotionPro brand that the post referred to. Should be available at any motorcycle shop or easy to find online. I don't think it can empty from one side of the tankto the other, just an extension of the petcock fuel tube to the other side of the tank. Shouldn't need a check valve, one more thing to go wrong anyway IMO.

DirtyErnie wrote:BTW anyone know if this is normal for the filter screen to look this way?!

When I pulled my stock tank and installed my Clarke 4.3 my petcock and strainer looked just like this. So I'm guessing it's pretty normal.